US11121399B2 - Battery cell and method of manufacturing a battery cell - Google Patents

Battery cell and method of manufacturing a battery cell Download PDF

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Publication number
US11121399B2
US11121399B2 US16/468,970 US201816468970A US11121399B2 US 11121399 B2 US11121399 B2 US 11121399B2 US 201816468970 A US201816468970 A US 201816468970A US 11121399 B2 US11121399 B2 US 11121399B2
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United States
Prior art keywords
electrode
tabs
plates
assembly
electrode tabs
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US16/468,970
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US20200083557A1 (en
Inventor
Martin Gerlach
Juergen Herold
Florian Postler
Christoph Schlund
Franz Brieger
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GS Yuasa International Ltd
Original Assignee
Robert Bosch GmbH
GS Yuasa International Ltd
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Assigned to GS YUASA INTERNATIONAL LTD, ROBERT BOSCH GMBH reassignment GS YUASA INTERNATIONAL LTD ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: Brieger, Franz, GERLACH, MARTIN, HEROLD, JUERGEN, POSTLER, Florian, Schlund, Christoph
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Assigned to GS YUASA INTERNATIONAL LTD reassignment GS YUASA INTERNATIONAL LTD ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: ROBERT BOSCH GMBH
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    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M10/00—Secondary cells; Manufacture thereof
    • H01M10/05—Accumulators with non-aqueous electrolyte
    • H01M10/052—Li-accumulators
    • H01M10/0525—Rocking-chair batteries, i.e. batteries with lithium insertion or intercalation in both electrodes; Lithium-ion batteries
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/10—Primary casings; Jackets or wrappings
    • H01M50/102—Primary casings; Jackets or wrappings characterised by their shape or physical structure
    • H01M50/103—Primary casings; Jackets or wrappings characterised by their shape or physical structure prismatic or rectangular
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/50—Current conducting connections for cells or batteries
    • H01M50/531—Electrode connections inside a battery casing
    • H01M50/538—Connection of several leads or tabs of wound or folded electrode stacks
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/50—Current conducting connections for cells or batteries
    • H01M50/531—Electrode connections inside a battery casing
    • H01M50/54—Connection of several leads or tabs of plate-like electrode stacks, e.g. electrode pole straps or bridges
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E60/00—Enabling technologies; Technologies with a potential or indirect contribution to GHG emissions mitigation
    • Y02E60/10—Energy storage using batteries
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P70/00—Climate change mitigation technologies in the production process for final industrial or consumer products
    • Y02P70/50—Manufacturing or production processes characterised by the final manufactured product

Definitions

  • the invention relates to a battery cell and to a method of manufacturing a battery cell.
  • battery and “battery cell” are used. These expressions are understood to encompass primary cells as well as secondary cells, i.e. accumulator cells.
  • a battery typically comprises a set of battery cells electronically linked to each other.
  • Jelly rolls or stacked battery cells of the lithium ion type typically consist of cathode electrode material on an aluminum foil (positive electrode), anode electrode material on a copper foil (negative electrode) and a separator soaked in electrolyte.
  • the jelly roll is made by rolling these elements together.
  • the stacked battery cell is created by stacking these elements in layers on one another.
  • the current collector tabs of the jelly rolls or stacks, hereinafter also called electrode tabs, are then connected with terminals and the complete assembly is sealed hermetically in aluminum or steel cans.
  • the lithium ions are migrating from the cathode by dint of electrolyte across the separator to the anode simultaneously with an electron flow in the same direction on the external circuit. During discharge, these processes are taking place in the opposite direction.
  • US 2015/0364727 shows a rechargeable battery including a plurality of electrode assemblies arranged in a case.
  • the electrode tabs are welded to a bottom surface of a flange of a terminal connected to the cap assembly.
  • the electrode tabs are bent at least once in a direction parallel to the first and second electrode plates.
  • US 2007/0105015 discloses a U-shaped electrode lead via which a terminal for a battery cover is connected to an electrode of a power-generating element.
  • the electrode lead is bent twice in a direction parallel to the first and second electrode plates.
  • the present invention proposes a battery cell, in particular a prismatic lithium ion cell, the battery cell comprising an electrode assembly, a battery case for housing the electrode assembly and a cap assembly for closing the battery case, the cap assembly comprising a set of terminals arranged thereon.
  • the electrode assembly comprises first electrode plates, separator plates and second electrode plates stacked on one another. Electrode tabs are provided to electrically connect the electrode assembly with the terminals. The electrode tabs are bent at least once in a direction normal to the first and second electrode plates.
  • the term “normal to the first and second electrode plates” is understood as follows:
  • the electrodes are essentially plate-like and typically consist of active material on metal foils.
  • the cathode electrode material may be coated on an aluminum foil, and the anode electrode material may be coated on a copper foil.
  • the plates are stacked on one another such that they are arranged in parallel. The direction perpendicular to the plates is the normal direction.
  • the electrode tabs being bent in the direction normal to the first and second electrode plates means that the folding line is perpendicular to the plane of the electrode plates.
  • the electrode assembly comprises a first and a second electrode step. Two stacks are considered to minimize the scrap rate in the production line. The stacks are stacked on one another.
  • the electrode tabs of the first stack are first folded onto the electrode tabs of the second stack and then bent at least once in the direction normal to the first and second electrode plates. Once folded, the area of the folds is more compact. Furthermore, the electrode tabs of the electrodes being folded on one another, allows for a lesser number of tabs to be connected with the terminals. Furthermore, a lesser number of tabs to be connected with the terminals leads to a higher welding efficiency
  • the electrode tabs are directly connected to the terminals.
  • an additional connection part e.g. connection part 7 in US 2007/0105015.
  • the specific folded arrangement results in a lowering of the height of the folded area because welding of the electrode tabs to the additional connection part is not required. Therefore, for a fixed total height of the battery cell, the relative height of the electrode assembly can be increased.
  • At least one isolating member is arranged on the electrode tabs.
  • the isolating member can be arranged on the electrode tabs of the first stack folded on the electrode tabs of the second stack.
  • the electrode tabs are provided at the corner of the electrode assembly.
  • An advantage of this embodiment is that the terminals of the cap assembly can also be arranged more closely to the edge of the cap assembly such that the elements from the center of the cap assembly, in particular the bursting membrane, may be designed more freely, e.g. the bursting membrane can be designed larger.
  • the invention provides a method of manufacturing a battery cell, in particular a prismatic lithium ion cell, the method comprising a step of providing an electrode assembly, where the electrode assembly comprises first electrode plates, separator plates and second electrode plates stacked on one another, the electrode plates being provided with electrode tabs for the external electric connection of the electrode assembly, a step of bending the electrode tabs at least once in a direction normal to the first and second electrode plates, a step of providing a cap assembly for closing the battery case, the cap assembly comprising a set of terminals arranged thereon, a step of electrically connecting the electrode tabs with the terminals, a step of providing a battery case for housing the electrode assembly, a step of housing the electrode assembly in the battery case, and a step of closing the battery case with the cap assembly.
  • the method of manufacturing the battery cell may be finished by the steps of filling the battery case with a liquid electrolyte and by sealing the battery case hermetically.
  • An advantage of using the cap plate fixation according to the present invention is that a rotating process of the cap plate can be avoided.
  • the invention allows for a vertical positioning of the cap plate relative to the stack.
  • the electrode assembly comprises a first and a second stack.
  • the method may then further comprise a step of folding the electrode tabs of the first stack onto the electrode tabs of the second stack, the step being followed by the step of bending the electrode tabs at least once in the direction normal to the first and second electrode plates.
  • the electrode tabs extend over the edges of the electrode assembly before being bent at least once in the direction normal to the first and second electrode plates. Since free-standing protruding electrode tabs can be easily handled by machines, this allows for easy manufacture.
  • the electrode tabs extend towards the center of the electrode assembly before being bent at least once in the direction normal to the first and second electrode plates.
  • the step of electrically connecting the electrode tabs with the terminals comprises laser welding, ultrasound welding or clinching technology.
  • the invention allows for an increased active area of electrodes as well as of a reduction of dead volume and, consequently, an increase in the overall energy density of the battery cell.
  • the invention allows for a cheap and less complicated method of manufacturing such a battery cell.
  • FIG. 1A shows a side view of a first electrode plate having an electrode tab according to a first embodiment of the invention
  • FIG. 1B shows a side view of a second electrode plate having an electrode tab according to a first embodiment of the invention
  • FIG. 2A shows a side view of a first electrode plate having an electrode tab according to a second embodiment of the invention
  • FIG. 2B shows a side view of a second electrode plate having an electrode tab according to a second embodiment of the invention
  • FIG. 3A shows a perspective view of an electrode assembly according to an embodiment of the invention at a first step of a manufacturing process
  • FIG. 3B shows a perspective view of an electrode assembly according to an embodiment of the invention at a second step of a manufacturing process
  • FIG. 3C shows a perspective view of an electrode assembly according to an embodiment of the invention at a third step of a manufacturing process
  • FIG. 3D shows a perspective view of an electrode assembly according to an embodiment of the invention at a fourth step of a manufacturing process
  • FIG. 3E shows a perspective view of an battery cell according to an embodiment of the invention at a fifth step of a manufacturing process
  • FIG. 4A shows a side view of an arrangement of a section of a cap assembly and a corner section of an electrode assembly according to an embodiment of the invention at a first step of its assembling process
  • FIG. 4B shows a side view of an arrangement of a section of a cap assembly and a corner section of an electrode assembly according to an embodiment of the invention at a second step of its assembling process
  • FIG. 5 shows a perspective view of an electrode assembly according to another embodiment of the invention.
  • FIG. 1A shows a side view of a first electrode plate 14 having an electrode tab 12 according to an embodiment of the invention.
  • the first electrode plate 14 e.g. the anode, has a rectangular shape with sides a and b. The sides a and b can be of equal length.
  • the electrode tab 12 is arranged in the corner of the first electrode plate 14 . In the depicted embodiment, the electrode tab 12 is arranged close to the edge of the longer side a and protrudes therefrom.
  • Electrode tab 12 comprises a socket portion 22 , a protruding portion 20 , a bending portion 18 and a connecting portion 30 .
  • the protruding portion 20 defines the intermediate portion between the socket portion 22 and the bending portion 18 .
  • the bending portion 18 and connecting portion 30 are at a right angle to the socket portion 22 .
  • the connecting portion 30 is at the tip of the bending portion 18 . Its function will be explained more in detail with regard to FIG. 4 d.
  • FIG. 1B shows a side view of a second electrode plate 16 having an electrode tab 12 according to a first embodiment of the invention.
  • the second electrode plate 16 e.g. the cathode, has a rectangular shape with sides a and b. The sides a and b can be of equal length.
  • the electrode tab 12 also comprises the socket portion 22 , the protruding portion 20 and the bending portion 18 with the connecting portions 30 as the tip of the electrode tab 12 , as described with regards to FIG. 1A .
  • the electrode tab 12 of the second electrode plate 16 is arranged opposed to the respective electrode tab 12 of the first electrode plate 14 of FIG. 1A . In both electrode plates 14 , 16 the bending portion 18 extends over the edge of the side a.
  • FIGS. 2A and 2B show first and second electrode plates 14 , 16 according to an alternative embodiment of the invention.
  • the bending portion 18 and connecting portions 30 extend towards the center of the electrode plates 14 and 16 , respectively.
  • FIGS. 3A to 3E show steps of manufacturing a battery cell 2 .
  • FIG. 3A shows a perspective view of an electrode assembly 4 according to an embodiment of the invention at a first step of a manufacturing process.
  • the electrode assembly 4 comprises a first stack 24 and a second stack 26 stacked on top of each other (from a layer perspective).
  • the four electrode tabs 12 are folded inwards towards each other such that the electrode tabs 12 of the first stack 24 are folded onto the electrode tabs 12 of the second stack 26 .
  • the electrode tabs 12 of the second stack 26 are first folded down in the direction to the first stack 24 . The result of this step is shown in FIG. 3B . Next, the electrode tabs 12 of the first stack 24 are folded onto the electrode tabs 12 of the second stack 26 . The result of the step is shown in FIG. 3C .
  • an isolating member 28 is arranged on the folded electrode tabs 12 .
  • the isolating member 28 may essentially cover the whole top surface of the electrode assembly 4 .
  • FIG. 3D shows the electrode assembly 4 after bending the four electrode tabs 12 upwardly, i.e. in a direction normal to the first and second electrode plates 14 , 16 .
  • the connecting portions 30 are now bent such that they extend parallel to the top surface of the electrode assembly 4 .
  • FIG. 3E shows battery cell 2 comprising the battery case 6 and the cap assembly 8 .
  • the electrode assembly 4 (not depicted) is arranged in the battery case 6 .
  • the cap assembly 8 is positioned onto the electrode assembly 4 .
  • the cap assembly 8 comprises positive and negative terminals 10 which are positioned close to the edge of the cap assembly 8 and opposed to each other. In the center of the cap assembly 8 , a bursting membrane 32 is provided. Due to the external positioning of the terminals 10 , the bursting membrane 32 can be freely designed, in particular regarding its form and position on the cap assembly 8 .
  • the cap assembly 8 further comprises a fill-in opening 34 for the liquid electrolyte.
  • the method of manufacturing the battery cell 2 may comprise the step of electrically connecting the electrode tabs 12 with the terminals 10 first and then housing the electrode assembly 4 (not depicted) in the battery case 6 , or the steps being in the other order.
  • the assembly steps may be followed by the step of filling the battery case 6 with a liquid electrolyte and by the step of sealing the battery case 6 , e.g. by welding the battery case to the cap assembly 8 .
  • FIG. 4A shows a side view of an arrangement of a section of the cap assembly 8 and a corner section of the electrode assembly 4 according to an embodiment of the invention at a first step of its assembling process.
  • the bending portion 18 comprises a folding line 36 , which is normal to the first and second electrode plates 14 , 16 .
  • the connecting portion 30 is connected with a respective connecting element 38 of the cap assembly 8 , thereby providing the electrical connection to the terminal 10 .
  • FIG. 4B shows a side view of an arrangement of a section of a cap assembly 8 and a corner section of an electrode assembly 4 according to an embodiment of the invention at a second step of its assembling process.
  • the cap assembly 8 is closely pressed to the electrode assembly 4 thus reducing the volume between them.
  • FIG. 5 shows a perspective view of an electrode assembly 4 according to another embodiment of the invention.
  • the isolating member 28 is provided in form of two isolation tapes 40 applied on top of the electrode assembly.
  • the isolation tapes 40 cover the areas where the electrode tabs 12 have been folded onto each other, e.g. the protruding portions 20 .

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  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Electrochemistry (AREA)
  • General Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Materials Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Connection Of Batteries Or Terminals (AREA)
  • Secondary Cells (AREA)
US16/468,970 2017-01-19 2018-01-15 Battery cell and method of manufacturing a battery cell Active 2038-06-10 US11121399B2 (en)

Applications Claiming Priority (4)

Application Number Priority Date Filing Date Title
EP17152144.6A EP3352249B1 (en) 2017-01-19 2017-01-19 Battery cell and method of manufacturing a battery cell
EP17152144.6 2017-01-19
EP17152144 2017-01-19
PCT/EP2018/050896 WO2018134157A1 (en) 2017-01-19 2018-01-15 Battery cell and method of manufacturing a battery cell

Publications (2)

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US20200083557A1 US20200083557A1 (en) 2020-03-12
US11121399B2 true US11121399B2 (en) 2021-09-14

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US16/468,970 Active 2038-06-10 US11121399B2 (en) 2017-01-19 2018-01-15 Battery cell and method of manufacturing a battery cell

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US (1) US11121399B2 (zh)
EP (1) EP3352249B1 (zh)
KR (1) KR20190101372A (zh)
CN (1) CN110192292B (zh)
HU (1) HUE061626T2 (zh)
WO (1) WO2018134157A1 (zh)

Families Citing this family (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
KR20240001371A (ko) 2022-06-27 2024-01-03 현대자동차주식회사 배터리 팩 조립장치 및 조립방법

Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20020094478A1 (en) 2000-12-02 2002-07-18 Arthur Holland Electrode with flag-shaped tab
JP2005190885A (ja) 2003-12-26 2005-07-14 Toyota Motor Corp ラミネート電池モジュールとその製造方法
US20090094478A1 (en) 2007-10-05 2009-04-09 International Business Machines Corporation Recovery of application faults in a mirrored application environment
US20130216872A1 (en) 2012-02-21 2013-08-22 Johnson Controls Technology Company Prismatic electrochemical cell
US20160036009A1 (en) * 2014-07-30 2016-02-04 Samsung Sdi Co., Ltd. Rechargeable battery and manufacturing method thereof

Family Cites Families (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP4556428B2 (ja) 2003-12-24 2010-10-06 株式会社Ｇｓユアサ 電池
US20060166088A1 (en) * 2005-01-26 2006-07-27 Hokanson Karl E Electrode connector tabs
DE102005007179A1 (de) * 2005-02-14 2006-08-24 Biotronik Crm Patent Ag Galvanische Zelle
KR102177505B1 (ko) 2014-06-17 2020-11-11 삼성에스디아이 주식회사 이차 전지

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20020094478A1 (en) 2000-12-02 2002-07-18 Arthur Holland Electrode with flag-shaped tab
JP2005190885A (ja) 2003-12-26 2005-07-14 Toyota Motor Corp ラミネート電池モジュールとその製造方法
US20090094478A1 (en) 2007-10-05 2009-04-09 International Business Machines Corporation Recovery of application faults in a mirrored application environment
US20130216872A1 (en) 2012-02-21 2013-08-22 Johnson Controls Technology Company Prismatic electrochemical cell
US20160036009A1 (en) * 2014-07-30 2016-02-04 Samsung Sdi Co., Ltd. Rechargeable battery and manufacturing method thereof

Non-Patent Citations (2)

* Cited by examiner, † Cited by third party
Title
European Office Action corresponding to European application No. 17 152 144.6 dated May 3, 2020 (6 pages).
International Search Report corresponding to international application No. PCT/EP2018/050896 dated Mar. 9, 2018 (3 pages).

Also Published As

Publication number Publication date
CN110192292A (zh) 2019-08-30
HUE061626T2 (hu) 2023-07-28
CN110192292B (zh) 2022-10-04
US20200083557A1 (en) 2020-03-12
KR20190101372A (ko) 2019-08-30
EP3352249A1 (en) 2018-07-25
WO2018134157A1 (en) 2018-07-26
EP3352249B1 (en) 2022-12-28

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